Additive manufacturing system and method of manufacture

Abstract

An additive manufacturing method includes segmenting a CAD file of an component along an build interface to define at least a first component segment and a second component segment each of the first component segment and the second component segment sized to fit within an additive manufacturing build chamber; additive manufacturing the first component segment and the second component segment within the build chamber; and bonding the first component segment and the second component segment to form the component.

What is claimed is: 
     
       1. An additive manufacturing method for an augmentor vane, comprising:
 selecting a build interface in an electronic file for a one-piece previously designed additively manufactured augmentor vane larger than an additive manufacturing build chamber, the build interface selected to avoid operational impact to the augmentor vane; 
 electronically segregating the electronic file representative of the augmentor vane along the build interface to define at least a first additively manufactured component segment and a second additively manufactured component segment, each of the first additively manufactured component segment and the second additively manufactured component segment are sized to fit simultaneously within an additive manufacturing build chamber, the first additively manufactured component segment different than the second additively manufactured component segment; 
 simultaneously additive manufacturing the first component segment and the second component segment within the additive manufacturing build chamber based on the defined first additively manufactured component segment and second additively manufactured component segment; and 
 bonding the first component segment and the second component segment outside of the additive manufacturing build chamber to form the augmentor vane. 
 
     
     
       2. The method as recited in  claim 1 , further comprising modifying the first additively manufactured component segment to include a sacrificial material portion to at least one of the the first additively manufactured component segment and the second additively manufactured component segment beyond the build interface. 
     
     
       3. The method as recited in  claim 2 , further comprising removing the sacrificial material portion during the bonding. 
     
     
       4. The method as recited in  claim 1 , further comprising modifying the first additively manufactured component segment and/or the second additively manufactured component segment to add thickness within the first component segment and/or the second component segment along the build interface. 
     
     
       5. The method as recited in  claim 1 , wherein selecting the build interface comprises defining the build interface along an internal rib. 
     
     
       6. The method as recited in  claim 1 , wherein selecting the build interface comprises defining the build interface at least partially around an aperture. 
     
     
       7. The method as recited in  claim 1 , wherein selecting the build interface comprises defining the build interface across the augmentor vane. 
     
     
       8. The method as recited in  claim 1 , wherein selecting the build interface comprises defining the build interface transverse to a longitudinal length of the augmentor vane.